Microbiological Validation of Microwave-Circulated Water Combination Heating Technology by Inoculated Pack Studies

Critical assessment of methods for measurement of temperature profiles and heat load history in microwave heating processes-A review

Limitations of microwave processing due to inhomogeneities of power input and energy absorption have been widely described. Over- and underheated product areas influence reproducibility, product quality, and possibly safety. Although a broad range of methods is available for temperature measurement and evaluation of time/temperature effects, none of them is sufficiently able to detect temperature differences and thermally induced effects within the product caused by inhomogeneous heating. The purpose of this review is to critically assess different methods of temperature measurement for their suitability for different microwave applications, namely metallic temperature sensors, thermal imaging, pyrometer measurement, fiber optic sensors, microwave radiometry, magnetic resonance imaging, liquid crystal thermography, thermal paper, and biological and chemical time-temperature indicators. These methods are evaluated according to their advantages and limitations, method characteristics, and potential interference with the electric field. Special attention is given to spatial resolution, accuracy, handling, and purpose of measurement, that is, development work or online production control. Differences of methods and examples of practical application and failure in microwave-assisted food processing are discussed with a special focus on microwave pasteurization and microwave-assisted drying. Based on this assessment, it is suggested that infrared cameras for measuring temperature distribution at the product surface and partially inside the product in combination with a chemical time/temperature indicator (e.g., Maillard reaction, generating heat-induced color variations, depending on local energy absorption) appear to be the most appropriate system for future practical application in microwave food process control, microwave system development, and product design. Reliable detection of inhomogeneous heating is a prerequisite to counteracte inhomogeneity by a targeted adjustment of process and product parameters in microwave applications.

Recent developments in low-moisture foods: microbial validation studies of thermal pasteurization processes

Outbreaks associated with low-moisture foods (e.g., wheat flour, nuts, and cereals) have urged the development of novel technologies and re-validation of legacy pasteurization process. For various thermal pasteurization processes, they share same scientific facts (e.g., bacterial heat resistance increased at reduced water activity) and guidelines. However, they also face specific challenges because of their different heat transfer mechanisms, processing conditions, or associated low-moisture foods' formulations. In this article, we first introduced the general structural for validating a thermal process and the shared basic information that would support our understanding of the key elements of each thermal process. Then, we reviewed the current progress of validation studies of 7 individual heating technologies (drying roasting, radiofrequency-assisted pasteurization, superheated steam, etc.) and the combined treatments (e.g., infrared and hot air). Last, we discussed knowledge gaps that require more scientific data in the future studies. We aimed to provide a process-centric view point of thermal pasteurization studies of low-moisture foods. The information could provide detailed protocol for process developers, operators, and managers to enhance low-moisture foods safety.

Unlocking Potentials of Microwaves for Food Safety and Quality

Microwave is an effective means to deliver energy to food through polymeric package materials, offering potential for developing short-time in-package sterilization and pasteurization processes. The complex physics related to microwave propagation and microwave heating require special attention to the design of process systems and development of thermal processes in compliance with regulatory requirements for food safety. This article describes the basic microwave properties relevant to heating uniformity and system design, and provides a historical overview on the development of microwave-assisted thermal sterilization (MATS) and pasteurization systems in research laboratories and used in food plants. It presents recent activities on the development of 915 MHz single-mode MATS technology, the procedures leading to regulatory acceptance, and sensory results of the processed products. The article discusses needs for further efforts to bridge remaining knowledge gaps and facilitate transfer of academic research to industrial implementation.

Mitochondrial DNA Fragmentation as a Molecular Tool to Monitor Thermal Processing of Plant-Derived, Low-Acid Foods, and Biomaterials

Cycle threshold (Ct) increase, quantifying plant-derived DNA fragmentation, was evaluated for its utility as a time-temperature integrator. This novel approach to monitoring thermal processing of fresh, plant-based foods represents a paradigm shift. Instead of using quantitative polymerase chain reaction (qPCR) to detect pathogens, identify adulterants, or authenticate ingredients, this rapid technique was used to quantify the fragmentation of an intrinsic plant mitochondrial DNA (mtDNA) gene over time-temperature treatments. Universal primers were developed which amplified a mitochondrial gene common to plants (atp1). These consensus primers produced a robust qPCR signal in 10 vegetables, 6 fruits, 3 types of nuts, and a biofuel precursor. Using sweet potato (Ipomoea batatas) puree as a model low-acid product and simple linear regression, Ct value was highly correlated to time-temperature treatment (R(2) = 0.87); the logarithmic reduction (log CFU/mL) of the spore-forming Clostridium botulinum surrogate, Geobacillus stearothermophilus (R(2) = 0.87); and cumulative F-value (min) in a canned retort process (R(2) = 0.88), all comparisons conducted at 121 °C. D121 and z-values were determined for G. stearothermophilus ATCC 7953 and were 2.71 min and 11.0 °C, respectively. D121 and z-values for a 174-bp universal plant amplicon were 11.3 min and 9.17 °C, respectively, for mtDNA from sweet potato puree. We present these data as proof-of-concept for a molecular tool that can be used as a rapid, presumptive method for monitoring thermal processing in low-acid plant products.

Clostridium sporogenes PA 3679 and its uses in the derivation of thermal processing schedules for low-acid shelf-stable foods and as a research model for proteolytic Clostridium botulinum

The putrefactive anaerobe Clostridium sporogenes PA 3679 has been widely used as a nontoxigenic surrogate for proteolytic Clostridium botulinum in the validation of thermal processes for low-acid shelf-stable foods, as a target organism in the derivation of thermal processes that reduce the risk of spoilage of such foods to an acceptable level, and as a research model for proteolytic strains of C. botulinum. Despite the importance of this organism, our knowledge of it has remained fragmented. In this article we draw together the literature associated with PA 3679 and discuss the identity of this organism, the phylogenetic relationships that exist between PA 3679 and various strains of C. sporogenes and proteolytic C. botulinum, the heat resistance characteristics of PA 3679, the advantages and limitations associated with its use in the derivation of thermal processing schedules, and the knowledge gaps and opportunities that exist with regard to its use as a research model for proteolytic C. botulinum. Phylogenetic analysis reviewed here suggests that PA 3679 is more closely related to various strains of proteolytic C. botulinum than to selected strains, including the type strain, of C. sporogenes. Even though PA 3679 is demonstrably nontoxigenic, the genetic basis of this nontoxigenic status remains to be elucidated, and the genetic sequence of this microorganism appears to be the key knowledge gap remaining to be filled. Our comprehensive review of comparative heat resistance data gathered for PA 3679 and proteolytic strains of C. botulinum over the past 100 years supports the practice of using PA 3679 as a (typically fail-safe) thermal processing surrogate for proteolytic C. botulinum.

Comparison of viability and heat resistance of Clostridium sporogenes stored at different temperatures

The objective of this study was to determine the influence of storage temperature on the viability and heat resistance of Clostridium sporogenes spores. Spore suspension containing both spores and vegetative cells was divided into 3 groups to be stored at different temperatures of -20 (freezing), 4 (refrigerating), and 25 degrees C (ambient temperature). Samples stored for different times within the 2 mo were tested for viability by comparison of colony counts on plates and for heat resistance by determining D values at 121 degrees C. No significant differences were found in the viability of vegetative cells during the storage period, regardless of storage temperatures tested, while the viability of the spores stored for more than 4 wk was significantly higher at 4 degrees C than at -20 degrees C. The heat resistance of spores stored at 4 degrees C for more than 4 wk was remarkably higher than that at 25 degrees C, but similar to that at -20 degrees C throughout the storage period. Consequently, it turned out that a refrigerating temperature of 4 degrees C is satisfactory for storage of C. sporogenes spores in maintaining viability and heat resistance. This study suggests that storage temperature influences the viability and heat resistance of C. sporogenes spores.

Effects of minerals on sporulation and heat resistance of Clostridium sporogenes

In this study, various mineral supplements, such as chloride salts (CaCl2, MgCl2, MnCl2, FeCl2 and KCl) supplying cations and calcium salts (CaCl2, CaCO3, CaSO4, Ca(OH)2 and CaHPO4) supplying anions, were tested if they could stimulate the sporulation of Clostridium sporogenes, a surrogate microorganism for C. botulinum. Of the cations tested, the addition of CaCl2 showed a slightly, but not significantly, greater increase in spore levels within 3 weeks of incubation, compared to that of the other cations. The optimum concentration of CaCl2 was 0.5%, which yielded nearly 10(4) CFU/ml of spores. Of the anions tested, CaCO3 promoted sporulation within one week, which was the most effective compound for promoting rapid sporulation among the minerals tested. CaSO4 produced a pattern of sporulation similar to that of CaCl2. While CaHPO4 resulted in the maximum production of spores after 4 weeks, Ca(OH)2 failed to induce sporulation. With an optimized concentration of 0.5% CaCO3, the spore yield was approximately 10(5) CFU/ml. The spores prepared in sporulation medium with CaCO3 (pH 5.0) had slightly, but not significantly, higher D values than those produced with CaCl2 (pH 5.0) at temperatures ranging from 113 to 121 degrees C. However, no significant differences were observed in Z values (both 10.76 degrees C). In a large scale spore production, D(121 degrees C) values of the spore crops prepared with CaCl2 and CaCO3 and resuspended in phosphate buffer (pH 7.0) were found to be both 0.92 min. In conclusion, our data suggest that CaCO3 is highly effective in reducing sporulation time as well as enhancing heat resistance.

Microwave and Radio Frequency Heating

This paper brings to perspective issues related to research initiatives for the application of microwave (MW) and radiofrequency (RF) applications in foods. Both MW (300 MHz and 300 GHz) and RF waves (3 kHz — 300 MHz) are part of the electromagnetic spectrum that result in heating of dielectric materials by induced molecular vibration as a result of dipole rotation or ionic polarization. They have been credited with volumetric heat generation resulting in rapid heating of foodstuffs. Due to their lower frequency levels, RF waves have a larger penetration depth than MW and hence could find better application in larger size foods. Besides the popular domestic use of MW ovens, commercialized applications of MW/RF heating include blanching, tempering, pasteurization, sterilization, drying, rapid extraction, enhanced reaction kinetics, selective heating, disinfestations, etc. This paper reviews the current status and research needs for in-packaged sterilization technologies for commercial applications. Technological challenges include process equipment design, microbial destruction and enzyme inactivation kinetics, temperature and process monitoring, and achieving of temperature uniformity. Other issues also relate to the use of packaging material in in-package sterilization applications, package/container concerns in domestic MW ovens, receptor technology for creating dry-oven conditions, modeling and time-temperature process integrators. There is also the issue of non-thermal and enhanced thermal effects of microwave heating on destruction kinetics.

Morphological study of heat-sensitive and heat-resistant spores of Clostridium sporogenes, using transmission electron microscopy

To investigate the primary structural determinants affecting heat resistance of Clostridium sporogenes spores, electron micrographs of heat-sensitive (D121 degrees C = 0.56 min) and heat-resistant (D121 degrees C = 0.93 min) spores of C. sporogenes were taken with a transmission electron microscope. The mean thickness (+/- standard deviation [SD]) of coat layers and cortex regions of heat-sensitive spores were 82.9 +/- 14.5 and 86.0 +/- 22.7 nm, while those of heat-resistant spores were 106.9 +/- 45.7 and 111.7 +/- 32.1 nm, respectively. The thickness of coat (P = 0.031) and cortex (P = 0.006) showed statistically significant differences, suggesting that heat-resistant spores have a thicker coat and cortex than do heat-sensitive spores. The mean sizes (+/- SD) of cores were 467.0 +/- 88.7 nm for heat-sensitive spores and 460.2 +/- 98.5 nm for heat-resistant spores, respectively, which showed no statistically significant differences. The ratios (+/- SD) of the core size to the sporoplast size were 0.84 +/- 0.05 for heat-sensitive spores and 0.80 +/- 0.07 for heat-resistant spores, respectively, showing statistically significant differences (P = 0.030), which indicated that the ratio is negatively related to heat resistance. Accordingly, the structural components of heat-sensitive spores were severely damaged by heat treatment, whereas those of heat-resistant spores were unlysed under the same conditions. Based on the structural analyses of spores, it was elucidated that the thickness of coat layer and cortex region are significantly correlated with heat resistance of C. sporogenes spores, and that cortex region plays a major role in protecting the spore from heat damage.

Inactivation of Listeria innocua in nisin-treated salmon (Oncorhynchus keta) and sturgeon (Acipenser transmontanus) caviar heated by radio frequency

Recent regulatory concerns about the presence of the pathogen Listeria monocytogenes in ready-to-eat aquatic foods such as caviar has prompted the development of postpackaging pasteurization processes. However, caviar is heat labile, and conventional pasteurization processes affect the texture, color, and flavor of these foods negatively. In this study, chum salmon (Oncorhynchus keta, 2.5% total salt) caviar or ikura and sturgeon (Acipenser transmontanus, 3.5% total salt) caviar were inoculated with three strains of Listeria innocua in stationary phase at a level of more than 10(7) CFU/g. L innocua strains were used because they exhibit an equivalent response to L monocytogenes for many physicochemical processing treatments, including heat treatment. The products were treated by immersion in 500 IU/ml nisin solution and heat processed (an 8-D process without nisin or a 4-D process with 500 IU/ml nisin) in a newly developed radio frequency (RF; 27 MHz) heating method at 60, 63, and 65 degrees C. RF heating along with nisin acted synergistically to inactivate L. innocua cells and total mesophilic microorganisms. In the RF-nisin treatment at 65 degrees C, no surviving L. innocua microbes were recovered in sturgeon caviar or ikura. The come-up times in the RF-heated product were significantly lower compared with the water bath-heated caviar at all treatment temperatures. The visual quality of the caviar products treated by RF with or without nisin was comparable to the untreated control.